Heat exchanger element and method for the production

ABSTRACT

To provide heat exchanger elements which allow the creation of Enthalpy exchangers whereby the efficiency of sensible energy exchange and latent energy exchange can he varied and controlled and especially improved, a method for the production of heat exchanger elements is provided including
         a) producing a plate element with defined outer dimensions and corrugations in the area within a border,   b) perforating the plate in predefined areas and in predefined dimensions,   c) filling the perforations with a polymer with latent energy recovery capability and   d) curing the polymer.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/744,917, filed Jan. 18, 2013, and claims priority under 35 U.S.C. §119 to European Patent Application No. 12000365.2, filed Jan. 20, 2012,each of which is hereby incorporated by reference in its entirety.

The present invention refers to heat exchanger elements. Furthermore,the invention discloses a method for the production of heat exchangerelements. Finally, the invention refers to a heat exchanger includinginventive heat exchanger elements.

It is state of the art to use different kinds of heat exchangers fordifferent purposes. Usually, heat exchangers are used to recover heatenergy from one fluid or medium into another one. This kind of heatenergy is celled sensible energy. The heat energy or sensible energy ofone fluid, normally air, is recovered into another one which is runningadjacent, e.g. parallel, counter or cross flow, to the first where thefluid is at lower temperature. By reversing fluid flows, the exchangebetween the two will generate a cooler fluid. Heat exchangers used forsensible energy recovery are usually made of metal or plastic plates.There are different types as there can be cross flow, parallel flow orcounter flow configurations. The plates are defining flow channelsbetween themselves so that the fluids can flow between the plates. Suchdevices are e.g. used in residential and commercial ventilation (HRV).

Another type of energy exchangers refers to the so called latent energywhich is the moisture. To exchange the latent energy it is known to usedesiccant coated metal or plastic substrates or membranes made fromdesiccant impregnated cellulose or polymer. Between plates made fromcellulose Of polymer, air passages are defined or created to allow thefluids to pass along the surface of the plates, thereby transferringmoisture from one fluid to the other one. As the membranes usually naveno structural strength, it is known to combine the membranes with framesor grids which thereby define spacings between the membranes.

In case of a combination of the above, the energy exchangers are called.Enthalpy exchanger. Those Enthalpy exchangers allow for the exchange ofsensible and latent energy, resulting in Total Energy recovery.

Membrane materials as currently available are delivered by the roll. Themembrane material is the most critical part of an Enthalpy exchanger.The membrane must be fixed and sealed to a kind of grin or frame andarranged in a way to allow for a fluid to flow between each membranelayer. So, it is obvious that Enthalpy exchangers of the known art are acompromise. They will usually lose in sensible energy to gain in latentenergy as a result of the selective scope and characteristics ofcurrently used membranes.

Such a heat exchanger built from respective elements is e.g. WO02/072242 A1. On grids respective membranes made of fibres arepositioned. The grids are stapled thereby altering the direction of theplates in order to create different air flow directions.

In view of the mentioned state of the art it is an object of theinvention to provide heat exchanger elements and heat exchangers as wellas a method for the production of neat exchanger elements. The inventiveheat exchanger elements allows for the creation of Enthalpy exchangerswhereby the efficiency of sensible energy exchange and latent energyexchange can be varied and controlled and especially improved.

With the invention, the solution of the above mentioned object ispresented by a method for the production of heat exchanger elements asdisclosed herein. With regard to the heat exchanger element, the objectis solved by an element with the features as disclosed herein.Improvements and further features are disclosed herein.

According to the invention, a new hybrid exchanger element is providedwhich on one hand has enough structural strength and density to createair flow channels for any type of cross flow and/or counter flow energyexchanger, thereby allowing for the use of a structurally strongmateriel which is good for sensible energy exchange, on the other handby size and number of perforations or openings or holes it is possibleto define an area which is filled with a polymer solution with latentenergy exchange characteristics. It is obvious that the efficiency ofsensible energy exchange on one hand and latent energy exchange on theother hand can be defined, controlled and adapted to the respectiveneeds of the environment (dry air, humidity, outside temperature and thelike).

According to the invention, a plats element can be made of aluminum orplastic or combinations thereof. The element can be provided withcorrugations. Corrugations can be designed to optimize the efficiency topressure drop ratio. The corrugations can be chosen to allow forcreating flow channels between similar plates when those are stackedtogether. By the definition of ids corrugation, one advantage will hethe enhancement of the surface which is available for energy transfer.This can be built up as large as possible and can even reach an increaseof 100% and more. Furthermore, the corrugations can be designed in a wayto allow for the easy arrangement of counter flow or cross flowconfigurations, e.g. by choosing oriented corrugations and alternatingthe position of the plate.

The border of the plate defines an area where similar plates can befixed together in an appropriate way. This can be welding, e.g. laserwelding, ultra sound welding and/or folding, crimping and the like. Thisstabilises the rigidity of the package as well as allows to build up thedesired flow channels. The herder area can be flattened, tongue/groovesystem, profiled or rimmed to allow for a tight sealable connectionbetween plates.

The perforations can be performed at the time of the plate productione.g. integrally when the plate is molded or stamped or embossed orvacuum formed.

The polymer can be one according to the state of the art, e.g. like theproduct “Aquivion”, a trademark of Solvay or “Nexar”, a trademark ofKraton.

The material can be e.g. a ionomer in form of a copolymer produced fromtetrafluoroethylene, C₂F₄, and Ethanesulfonyl fluoride,1,1,2,2-tetrafluoro-2-[(trifluoroethenyl)-oxy], C₂F₃O—(CF₂)₂—SO₃F,sulfonated block copolymer.

However, the polymers can be adapted to the desired characteristic andfeatures.

According to the inventions, the polymer is supplied as a dispersion.The dispersion can be brought to the plate by thereby filling orcovering the holes or perforations with the polymer solution by way ofspray, dipping, serigraphy or any other lamination method it is obviousthat the amount or efficiency of latent energy recovery depends on thesurface provided by the holes or perforations, their shapes and theirlocations. So it is possible to adapt the heat exchanger plates to theenvironmental and functional conditions.

By using the highly heat conductive materials as the structural elementsfor the Enthalpy membrane, high sensible efficiency is ensured. Bydefining the perforations and choosing the polymer, high latent recoveryis ensured.

The corrugation/embossing of the plats increases the exchange surfacesignificantly

The perforated or opened portions of each plate can reach 70% or more,of the total surface area e.g. mosquito screen pattern. In such a case,the surface exceeds that of a flat membrane according to the state ofthe art), with minimal loss of the high sensible energy recoverycharacteristic of the exchanger plates A Total Energy recoveryefficiency of up to 85% can be reached in heating mode and 72% incooling mode. A number of finalized plates can be stacked together tobuild a package which, within a frame or housing, creates a heatexchanger according to the invention.

Combined sensible and latent energy to such a high Total Energy recoverylevel could, in some climatic zones, eliminate the need for a sensibleonly heat exchanger.

The polymer can be combined with additives to manifold and magnify itsattributes. It can be, for instance, efficiently anti-bacterial and canmeet fire resistance requirements (UL). Its viscosity can be adjusted toachieve the optimal tunable exchange features of the plate allowing ashigh a moisture exchange as possible.

It is obvious that the sensible energy transfer and the latent energytransfer capabilities of the heat exchanger are tunable and adjustable.The plates are adaptable to environmental conditions by the variablemosaic geometry of the perforations. E. g. an exchanger can be designedto operate at temperature under the freezing point (−10° C.) without icebuilt up only by choosing the right position of the perforations andpolymeric treatment of the constitutive plates.

The rigidity of the structural elements could make the plate and therebythe membrane capable of handling pressure differential up to 1 Kpa.within the exchanger. This advantage opens the door to larger exchangerconstructions for commercial applications.

The invention provides a simple method for the production of energyexchanger plates allowing sensible as well as latent energy exchange.The design and the adaptability of the plates allows for theconstruction and design of neat exchangers which are optimized withregard to the technical requirements and/or the environmentalconditions.

Stamped, corrugated, embossed or vacuum formed aluminum, stainlesssteel, resin based plates and/or plastic plates can be made using provenautomation technologies including the assembly, e.g. by vacuum grip, andseal, e.g. by laser welding, ultra sound welding, folding, crimping, toobtain packages of superposed rigid plates. The plates are washable,fire resistant, antibacterial, sealed e.g. leakage proof. They have allvaluable advantages that are necessary to create highly efficient heatexchangers.

The selective perforation of the plates and the air-tight casting of themosaic polymer micro membranes allows for the construction of structuralhybrid mosaic membranes. The plate perforation, too, can be performed bypre-programmed continuous laser processes, by mechanical systems likeneedle-roller and the like, or chemical etching processes.

Further features and aspects of the invention become obvious from thefollowing description of the drawings. The drawings show:

FIG. 1 a top view of one example for an embodiment of an exchanger plateaccording to the invention and

FIG. 2 a side view of the plate according to FIG. 1.

In the drawings, the same elements are designated by the same referencenumbers.

An exchanger plate 1 consists of a structural rigid plate 2 made fromaluminum, plastic or the like. Plate 2 has a rim 4 which is a flatsealable rim and can be deformed for sealing. Areas of the rim 4 areopened or deviated as shown by reference no. 5 to define e.g. a inletand outlet of a flow channel.

Within the rim area, corrugations 3 are stamped or embossed into theplate 2. When plates are sealed together, flow channels are defined. Inthe example, reference no. 5 designates areas with perforations.

For the purpose of clarity, only some of the perforation areas 6 andsome of the corrugated areas 3 are designated.

The heat exchanger element 1 shows a great surface tor heat exchangewhich is increased by the corrugations 3 which are corrugated in onedirection only and open on the other surface. Furthermore, theperforated areas 6 define a latent energy exchange area for the transferof moisture.

These plates will be stacked to build a heat exchanger e.g. forventilation systems to exchange heat from outgoing to incoming air (orvice versa for free cooling in summer) as well as humidity from outgoingto incoming air in winter (or vice versa for moisture reduction insummer or all year round in hot and humid climatic tones).

The drawings and the description do in no way restrict the invention andare meant for describing an example, only.

REFERENCE NUMERALS

-   -   1 neat exchanger element    -   2 plate    -   3 corrugation    -   4 border    -   5 opened border    -   6 perforations

What is claimed is:
 1. A method for the production of heat exchanger elements comprising: a) producing a plate element with defined outer dimensions and corrugations in the area within a border; b) perforating the plate in predefined areas and in predefined dimensions; c) filling the perforations with a polymer with latent energy recovery capability; and d) curing the polymer.
 2. The method according to claim 1, characterized in that the plate is aluminum.
 3. The method according to claim 1, characterized in that the plate is plastic.
 4. The method according to claim 1, characterized in that the plate is stamped.
 5. The method according to claim 1, characterized in that the plate is corrugated.
 6. The method according to claim 1, characterized in that the plate is molded.
 7. The method according to claim 1 characterized in that the plate is perforated by stamping.
 8. The method according to claim 7, characterized in that the perforation is formed during molding.
 9. The method according to claim 1, characterized in that the polymer is a sulfonated copolymer.
 10. The method according to claim 1, characterized in that the polymer is applied as dispersion.
 11. A heat exchanger element including a plate element with defined outer dimensions and corrugations in the area within a border, said plate element has perforations in predefined areas and in predefined dimensions, said perforations are filled with a polymer with latent energy recovery capability.
 12. The heat exchanger element according to claim 11, characterized in that the perforations are small holes.
 13. The heat exchanger element according to claim 12, characterized in that the perforated areas sum up to 70% of the total surface of the plate element.
 14. The heat exchanger element according to claim 11, characterized in that the polymer is a sulfonated copolymer.
 15. The heat exchanger element according to claim 11, characterized in that the plate dement has a border which allows gaslight connection to another similar plate element.
 16. The heat exchanger element according to claim 11, characterized in that the plate element has corrugations increasing the exchange surface up to 100%.
 17. The heat exchanger element according to claim 11, characterized in that the corrugations are oriented to guide a fluid flow.
 18. The heat exchanger with at least three plates like heat exchanger elements fixed to each other in parallel orientation to form two fluid paths allowing fluids to flow there through, characterized in that the plate like hear exchanger elements are elements according to claim
 11. 